Laminated Articles Having Discontinuous Adhesive Regions

ABSTRACT

Laminated articles that include a first textile and a functional film layer bonded together by an adhesive layer having a distinctive, discontinuous adhesive pattern is provided. The discontinuous adhesive pattern creates regions free or substantially free of adhesive that permits the laminate to preferentially bend in those regions. The adhesive regions, together with the non-adhesive regions, create a visible pattern on the surface of the laminate. A second textile may be bonded to the functional film layer opposing the first textile. The first textile or the film layer may be elastic, shrinkable, or expandable. In such embodiments, raised portions of the laminate corresponding to the non-adhesive regions and curled portions corresponding to the adhesive regions are visible. The laminated article is waterproof, liquid-proof, breathable, and aesthetically pleasing and demonstrates a reduction in stiffness, improved insulation properties, improved stretch properties and a reduction of noise associated with bending the article.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part U.S. patent application Ser.No. 13/843,682, filed Mar. 15, 2013, which, in turn, is acontinuation-in-part of U.S. patent application Ser. No. 13/432,613,filed Mar. 28, 2012, the content of which is hereby incorporated byreference in its entirety.

FIELD OF THE INVENTION

The present invention relates generally to laminated articles, and morespecifically, to laminated articles that include a textile layer and afilm layer bonded via an adhesive layer having a distinctive,discontinuous adhesive pattern.

Definitions

As used herein, the term “laminate” means an article comprising afunctional film or coating that is coated onto or adhered to at leastone layer of textile.

The terms “functional film”, “functional film layer”, and “film layer”are meant to denote a substance that provides properties that mayinclude, but are not limited to: a barrier to liquid (e.g., water)penetration, a barrier to penetration by chemical substances, a barrierto gas penetration, a barrier to particulate penetration, barrier to airpenetration (e.g., impermeability), odor control, antimicrobial,windproof, and breathability.

As used herein, the term “textile” is meant to denote any wovens,nonwovens, felts, fleece, or knits and can be composed of natural and/orsynthetic fiber materials and/or other fibers or flocking materials.

As used herein, a layer is considered “liquid-proof” if it preventsliquid penetration against a pressure of at least 0.07 bar for aduration of at least 3 minutes. The liquid penetration pressure ismeasured on a liquid-proof panel based on the same conditions describedwith respect to the Suter Test for Liquid-proof Fabrics describedherein.

As used herein, the term “breathable” or “breathability” refers tolaminates that have a Water Vapor Transmission Rate (WVTR) of at leastabout 1,000 grams/m² in 24 hours.

As used herein, the term “preferentially bends” means that one region ofthe laminate bends to a larger degree than a second region of thelaminate when identical or substantially identical forces are applied toboth regions. For instance, in the instant invention, preferentialbending occurs in the regions free or substantially free of adhesive(e.g., unbonded regions) when the free edges of the laminate are graspedand moved toward each other.

BACKGROUND OF THE INVENTION

Waterproof, breathable garments are well-known in the art. Thesegarments are often constructed from multiple layers in which each layeradds a certain functionality. For example, a garment could beconstructed using an outer textile layer, a waterproof, breathable filmlayer, and an inner textile layer. It is often desirable to have themultiple layers bonded together with an adhesive layer to create alaminate and prevent the layers from sliding past each other to give thelook and feel of a single-layered garment. The process of bonding thelayers together, however, has the detrimental effects of making thegarment stiffer and noisier when worn. This not only reduces theenjoyment of wearing these garments, but can also affect performance inapplications where noise control is critical, such as in hunting ormilitary applications.

In addition to the stiffness and noise concerns, there are other reasonsthat a uniformly bonded laminate may be undesirable. For instance, iftensions are not well-controlled during the lamination process, theresulting laminate can curl due to the residual stresses created duringlamination. Such curling of the laminate makes garment constructionproblematic as it is difficult to lay the pieces flat while sewing.Conversely, if the layers are not bonded together at all, the complexityof garment construction may increase due to each material having to becut and laid out separately.

Further concerns with uniformly bonded laminates arise when stretchproperties are desirable within waterproof, breathable garments andarticles. Issues ranging from fit to donning and doffing ease to comfortduring movement, to name but a few, can be significant challenges whenworking with uniformly bonded laminates. Conventional stretchablewaterproof breathable garments have been described in, for example, U.S.Pat. No. 4,443,511, and U.S. Pat. No. 4,935,287. Limitations still existwith respect to the high stretch forces required to stretch theseuniformly bonded laminate materials.

Therefore, a need in the art exists for a laminate article that canmaintain the positive attributes of a bonded, multi-layer article whilereducing noise, stiffness, stretch force and residual laminationstresses.

SUMMARY OF THE INVENTION

It is an object to provide a laminated article that includes (1) afunctional film layer, (2) a first textile; and (3) a first adhesivelayer bonding the functional film layer and the first textile. The firstadhesive layer contains two or more adhesive regions separated byregions that are substantially free of adhesive. The adhesive regionsmay contain a plurality of adhesive dots. In at least one embodiment,the adhesive dots are substantially the same size. The distance betweenadjacent adhesive dots within the adhesive regions is less than adistance between consecutive adhesive regions within the laminate. Inaddition, in at least one embodiment, the adhesive regions form at leastone distinctive shape that is repeated two or more times. Thedistinctive shape may be a geometric or abstract shape. Additionally,the laminated article preferentially bends in the regions substantiallyfree of adhesive. The adhesive regions may have a width greater thanabout 5 mm and the regions substantially free of adhesive may have awidth greater than about 2 mm. The adhesive regions may representgreater than or equal to at least 50% of the laminate area.

It is another object to provide a laminated article that includes (1) afunctional film layer, (2) a first textile, and (3) a first adhesivelayer bonding the functional film layer to the first textile. Theadhesive layer contains adhesive regions and regions substantially freeof adhesive that are interspaced between the adhesive regions. Theregions substantially free of adhesive have a width greater than about 2mm. Further, the laminated article preferentially bends in the regionsthat are substantially free of adhesive. In one exemplary embodiment, asecond textile is bonded to the functional film layer opposite the firstfilm layer by a second adhesive layer. An air gap is positioned betweenthe functional film layer and the second textile in raised, visibleportions that outline the adhesive regions. The adhesive regions mayeach contain a plurality of dots. A bending modulus of the regionssubstantially free of adhesive is at least 20% less than a bendingmodulus of the adhesive regions.

It is yet another object to provide a laminated article that includes(1) a functional film layer, (2) a first textile, and (3) a firstadhesive layer bonding the functional film layer and the first textile.The adhesive layer contains first adhesive regions and second adhesiveregions. In addition, the first adhesive regions contain an amount ofadhesive that is greater than an amount of adhesive present in thesecond adhesive regions. In one exemplary embodiment, the first adhesiveregions contain a plurality of adhesive dots. Also, the laminatedarticle has a bending modulus in the second adhesive regions that islower than a bending modulus in the first adhesive regions. The secondadhesive regions may be substantially free of adhesive. The distancebetween consecutive first adhesive regions is greater than about 2 mm.

It is a further object to provide a laminated article that includes afunctional film layer and a first textile bonded to the functional filmlayer by a first adhesive layer that includes (1) two or more adhesivedots and (2) a continuous path substantially free of adhesive. Thecontinuous path provides a region where the laminate preferentiallybends. In addition, each set of adhesive dots forms an adhesive region.The radius of curvature of each adhesive region is from about 2 mm toabout 50 mm. Also, the continuous path forms a raised, visible portionoutlining the adhesive regions in at least one exemplary embodiment. Asecond textile may be bonded to the functional film layer opposite thefirst textile by a second adhesive layer. In another exemplaryembodiment, at least one of the first textile and the adhesive dotscontain a fire retardant or fire resistant material.

It is also an object to provide a laminated article that includes (1) afunctional film layer and (2) a first textile bonded to the functionalfilm layer by a first adhesive layer. The first adhesive layer containsat least one first region having a first percent area coverage ofadhesive and at least one second region having a second percent areacoverage of adhesive. The first percent area coverage of adhesive isgreater than the second area coverage of adhesive. In exemplaryembodiments, the second adhesive region is free or substantially free ofadhesive. Additionally, the first region forms at least one distinctiveshape that is repeated two or more times. The second region may form araised, visible portion outlining the distinctive shape, which has ageometric or abstract form. In at least one embodiment, a second textileis bonded to the film layer opposite the first textile by a secondadhesive layer. An air gap may be positioned between the film layer andthe second textile in a raised, visible portion.

It is a further object to provide a method of forming a laminatedarticle that includes bonding a functional film layer and a firsttextile via a first adhesive layer where the first adhesive layercontains adhesive regions and regions substantially free of adhesive.The functional film may be a fluoropolymer. The regions substantiallyfree of adhesive are interspaced between the adhesive regions. In one ormore exemplary embodiment, the regions substantially free of adhesiveform a raised, visible portion outlining the adhesive regions. Theadhesive regions have at least one distinctive shape, which may berepeated two or more times. Additionally, the regions substantially freeof adhesive have a width greater than about 2 mm. Further, the laminatedarticle preferentially bends in the regions substantially free ofadhesive. The method may further include tensioning the functional filmprior to positioning the functional film on the first adhesive layer. Inat least one exemplary embodiment, the method also includes bonding asecond textile to the functional film opposite the first textile by asecond adhesive layer. An air gap may be positioned between thefunctional film layer and the second textile in the raised portion. Inan alternate embodiment, the adhesive regions are formed by pressing thetextile into a patterned rubber roll. Alternatively, a release paper maybe used to form the adhesive regions. In such an embodiment, the methodfurther includes (1) positioning a release paper on the first textileprior to applying the first adhesive layer and (2) removing the releasepaper from the first textile prior to positioning the functional film onthe first adhesive layer. In a further embodiment, a gravure roll isused to transfer the adhesive layer to the film layer. Further, thefirst textile or the first adhesive layer may include a fire retardantmaterial or fire resistant material.

It is also an object of the invention to provide a method of forming alaminated article that includes (1) tensioning an elastomeric film, (2)bonding a functional film layer and the tensioned elastomeric film tocreate a bonded elastomeric film layer, (3) tensioning the bondedelastomeric film layer and bonding it to a first textile by a firstadhesive layer and (4) allowing the laminated article to relax,resulting in a curling of the laminated article in the areascorresponding to the adhesive regions. The first adhesive layer containsadhesive regions and regions substantially free of adhesive. The regionssubstantially free of adhesive are interspaced between said adhesiveregions which have at least one distinctive shape. A distance betweenconsecutive the adhesive regions may be greater than about 2 mm. Inexemplary embodiments, the laminate has a stretch force at 20%elongation of less than three times the stretch force of said firsttextile. In addition, the laminate has a stretch force at 20% elongationof less than two times the stretch force of the functional film layer.

It is a further object of the present invention to provide a method offorming a laminated article that includes (1) tensioning a first textileto achieve reduction in width of the first textile, (2) bonding afunctional film layer and the first textile via a first adhesive layer,and (3) reducing the tension on the first textile and allowing the firsttextile to expand in a direction perpendicular to the direction oftension, which results in a bunching of the first textile in the regionssubstantially free of adhesive. The first adhesive layer containsadhesive regions and regions substantially free of adhesive. Also, theregions substantially free of adhesive are interspaced between theadhesive regions and the adhesive regions have at least one distinctiveshape.

It is a further object of the present invention to provide a method offorming a laminated article that includes (1) bonding a shrinkablefunctional film layer to a first textile via a first adhesive layer tofrom a laminated article, and (3) shrinking the functional film whichresults in a curling of the laminated article in the areas correspondingto the adhesive regions. The first adhesive layer contains adhesiveregions and regions substantially free of adhesive. Also, the regionssubstantially free of adhesive are interspaced between the adhesiveregions and the adhesive regions have at least one distinctive shape. Inexemplary embodiments, the laminate has a stretch force at 20%elongation of less than three times the stretch force of the firsttextile. The laminated article curls towards the functional film layer.In at least one exemplary embodiment, the first textile is shrinkableand the method further includes shrinking the first textile.

It is yet another object of the present invention to provide method offorming a laminated article that includes (1) bonding a functional filmlayer to a shrinkable textile via a first adhesive layer to from alaminated article, and (2) shrinking the textile which results in acurling of the laminated article in the areas corresponding to theadhesive regions. The first adhesive layer contains adhesive regions andregions substantially free of adhesive. The regions substantially freeof adhesive are interspaced between the adhesive regions and theadhesive regions have at least one distinctive shape. In exemplaryembodiments, the laminate has a stretch force at 20% elongation of lessthan three times the stretch force of the first textile.

It is an advantage that the laminated articles demonstrate a reductionin stiffness, improved insulation properties, improved specularreflection, and a reduction of noise associated with bending thearticle.

It is a further advantage that the laminated articles exhibit improvedstretch properties relative to conventional waterproof, breathablelaminate constructions. Additionally, laminated articles including aknitted textile which exhibit bunching, or the creation of a gap betweenthe knitted textile and the film layer, in the direction perpendicularto the knit rows of the textile for improved flexing of the article arealso contemplated.

It is a feature of the present invention that the film layer can be afluoropolymer.

It is also a feature of the present invention that the textile and/orthe adhesive may comprise a fire retardant or fire resistant material.

It is another feature of the present invention that the laminate has astretch force at 20% elongation of less than three times the stretchforce of the first textile.

It is yet another feature of the present invention that the laminate hasa stretch force at 20% elongation of less than two times the stretchforce of said functional film layer.

The foregoing and other objects, features, and advantages of theinvention will appear more fully hereinafter from a consideration of thedetailed description that follows. It is to be expressly understood,however, that the drawings are for illustrative purposes and are not tobe construed as defining the limits of the invention.

BRIEF DESCRIPTION OF THE FIGURES

The advantages of this invention will be apparent upon consideration ofthe following detailed disclosure of the invention, especially whentaken in conjunction with the accompanying drawings wherein:

FIG. 1 is a schematic illustration of a two-layer laminate havingdiscontinuous adhesive dots in the bonded regions according to at leastone exemplary embodiment of the invention;

FIG. 2 is a schematic illustration of a two-layer laminate having acontinuous adhesive in the bonded regions according to another exemplaryembodiment of the invention;

FIG. 3 is a top view of the laminate of FIG. 1 or 2 illustrating thepattern formed by the bonded and unbonded regions according to oneembodiment of the invention;

FIG. 4 is a schematic illustration of a three-layer laminate havingdiscontinuous adhesive dots in the bonded regions according to at leastone exemplary embodiment of the invention;

FIG. 5 is a schematic illustration of a three-layer laminate containingbonded and unbonded regions on both the top and bottom surfaces of thelaminate according to another exemplary embodiment of the invention;

FIG. 6 is a perspective view of a three-dimensional laminate accordingto at least one exemplary embodiment of the invention;

FIG. 7 is a schematic illustration of a two-layer laminate havingdiscontinuous adhesive dots in the bonded regions and raised portionscorresponding to the unbonded regions according to one embodiment of theinvention;

FIG. 8 is a schematic illustration of a three-layer laminate havingdiscontinuous adhesive dots in the bonded regions and raised portionscorresponding to the unbonded regions according to at least oneexemplary embodiment of the invention;

FIG. 9 is a schematic illustration of a three-layer laminate where thesecond textile forms air pockets within the laminate according toanother exemplary embodiment of the invention;

FIG. 10 is a schematic illustration of a laminate structure formed witha shrinkable or elastic film layer according to at least one exemplaryembodiment of the invention;

FIG. 11 is a schematic illustration of the laminate of FIG. 10 with asecond textile positioned on the film layer opposite the first textileaccording to one embodiment of the invention;

FIG. 12 is a schematic illustration of a release paper having therein ahexagonal pattern according to one exemplary embodiment of theinvention;

FIG. 13 is a schematic illustration of a process for forming atwo-layered laminate using release paper to apply a hexagonal adhesivepattern according to at least one exemplary embodiment of the invention;

FIG. 14 is a schematic illustration of a portion of a patterned rubberroll consisting of raised hexagonal areas separated by channelsaccording to one embodiment of the invention;

FIG. 15 is a schematic illustration of a process for forming athree-layered laminate according to another exemplary embodiment;

FIG. 16 is a schematic illustration of a method for determining theradius of curvature of the laminate of FIG. 7;

FIG. 17 is a schematic illustration of a portion of a gravure rollcontaining an adhesive pattern separated by non-adhesive areas accordingto one embodiment of the invention;

FIG. 18 is a schematic illustration of a process for forming atwo-layered laminate using a gravure roll to apply an adhesive patternaccording to at least one exemplary embodiment of the invention;

FIG. 19 is a schematic illustration of a release paper having therein awavy parallel line pattern according to one exemplary embodiment of theinvention;

FIG. 20 is a schematic illustration of a laminate structure whichexhibits bunching according to at least one exemplary embodiment of theinvention;

FIG. 21 is a schematic illustration of an exemplary adhesive regionwhere the adhesive dots have substantially the same diameter throughoutthe adhesive region;

FIG. 22 is a schematic illustration of an exemplary adhesive regionwhere the adhesive dots positioned on the outer portion of the adhesiveregion have a diameter that is larger than adhesive dots positioned inan inner portion of the adhesive region;

FIG. 23 is a schematic illustration of an exemplary adhesive regionwhere an outer portion of the adhesive region is formed of a continuousor substantially continuous band of adhesive surrounding a plurality ofadhesive dots having substantially the same diameter;

FIG. 24 is a schematic illustration of an exemplary adhesive regionwhere the adhesive is applied in a manner so as to form centrallylocated circular regions that are free or substantially free ofadhesive; and

FIG. 25 is a schematic illustration of an exemplary adhesive regionwhere the adhesive is applied to form a grid-like pattern within theadhesive region.

DETAILED DESCRIPTION OF THE INVENTION

Unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which the invention belongs. In the drawings, the thicknessof the lines, layers, and regions may be exaggerated for clarity. Itwill be understood that when an element such as a layer is referred toas being “on” another element, it can be directly on the other elementor intervening elements may also be present. Also, when an element isreferred to as being “adjacent” to another element, the element may bedirectly adjacent to the other element or intervening elements may bepresent. The terms “top”, “bottom”, “side”, and the like are used hereinfor the purpose of explanation only. Like numbers found throughout thefigures denote like elements. The terms “film layer” and “functionalfilm layer” may be used interchangeably herein. Also, the terms“laminate” and “laminated article” may be used interchangeably herein.In addition, the terms “bonded region” and adhesive region” may be usedinterchangeably herein.

The present invention is directed to laminated articles that include afirst textile and a functional film layer bonded via an adhesive layerhaving a distinctive, discontinuous adhesive pattern. The discontinuousadhesive pattern creates a visible, aesthetically pleasing surface onthe first textile. Additionally, the discontinuous adhesive patterncreates regions free or substantially free of adhesive within thelaminated article that permits the laminate to preferentially bend inthose regions. A second textile may optionally be bonded to the filmlayer on the side opposing the first textile by an adhesive. In at leastone exemplary embodiment, at least one of the first textile and the filmlayer is elastic or otherwise stretchable. The laminated article iswaterproof, liquid-proof, breathable, and demonstrates a reduction innoise generated by bending the article and an improvement in insulativevalue and spectral reflection.

The laminated articles of the present invention further exhibit asurprisingly low stretch force, as measured and described later herein,relative to the stretch force required to stretch the first textilealone. For comparison purposes, conventional uniformly laminatedmaterials promoted as having stretch properties can typically exhibitstretch forces on the order of at least 5 times (5×) greater than thestretch force of the first textile alone. The novel laminated articlesof the present invention may exhibit stretch forces which are on theorder of only three times (3×) or less greater than the stretch force ofthe first textile alone. In an alternative embodiment, laminatedarticles of the present invention may exhibit stretch forces which areon the order of only 2 times (2×) or less greater than the stretch forceof the first textile alone. Alternatively, embodiments of the laminatedarticles of the present invention may exhibit stretch forces which aresubstantially the same as (1×) or even less than the stretch force ofthe first textile alone. In even further alternative embodiments,stretch forces for the laminated article may be on the order of one half(0.5×) or less of the stretch force required to stretch the firsttextile alone. In other alternative embodiments, the stretch force maybe on the order of one third (0.33×) or less of the stretch forcerequired to stretch the first textile alone. Other embodiments of thepresent invention may exhibit stretch forces on the order of one sixth(0.16×) or less of the stretch force required to stretch the firsttextile alone.

In another embodiment of the invention, laminated articles including aknitted textile are contemplated which exhibit “bunching”, or thecreation of a gap between the knitted textile and the film layer in theunbonded regions, when the knitted textile expands in at least onedirection, resulting in increased thickness of the article.

Turning to FIG. 1, a two-layer laminate 10 according to one embodimentof the invention can best be seen. As shown in FIG. 1, a film layer 20has applied thereto an adhesive 30 to bond the first textile 40 to thefilm layer 20. It is to be appreciated that the adhesive 30 may beapplied to the film layer 20 or to the first textile 40 (or to both thefilm layer 20 and the first textile 40). For ease of discussion,application of the adhesive 30 to the film layer 20 is described herein.The adhesive 30 is applied to the film layer 20 in a distinctive,discontinuous pattern such that the adhesive 30 contains bonded(adhesive) regions 50 separated by unbonded (non-adhesive) regions 60.The adhesive 30 may be applied as a series of discontinuous dots, suchas shown in FIG. 1, or may be applied in a solid, continuous patternwithin the bonded regions 50 as depicted in FIG. 2.

The adhesive dots within the bonded regions 50 may have the same orsubstantially the same size or may vary in size within one bonded regionor from one bonded region to another. In an alternative embodiment, theadhesive dots may be distributed non-uniformly within the adhesiveregions. Other adhesive patterns within the bonded regions 50 such asgrids, lines, or other patterns are considered to be within the purviewof the invention, and such adhesive may be distributed uniformly ornon-uniformly within the adhesive region(s).

For example, the adhesive dots 40 may have substantially the samediameter throughout the bonded regions 50, such as is illustrated inFIG. 21. The distance between adjacent adhesive dots 41 within thebonded regions 50 may be less than a distance between consecutive bondedregions 50. Alternatively, the adhesive dots positioned on the outerportion of the bonded region 50 may have a diameter that is larger thanadhesive dots positioned in an inner portion of the bonded region 50.Looking at FIG. 22, it can be seen that the adhesive dots 42 have alarger diameter than adhesive dots 44. Additionally, as shown in FIG.22, the adhesive dots may get sequentially smaller in diameter from theouter portion of the bonded region 50 to the inner portion of the bondedregion 50. Also, the distance between dots 42, 44 may vary within thebonded region 50 (not illustrated).

In other embodiments, the adhesive 30 may be applied in both acontinuous and discontinuous manner within the adhesive region 50. Onesuch example is shown in FIG. 23 where an outer portion of the adhesiveregion 50 is formed of a continuous or substantially continuous band ofadhesive 46 surrounding a plurality of adhesive dots 48 havingsubstantially the same diameter. It is to be appreciated that theadhesive dots 48 located within the band of adhesive 46 may vary indiameter, may themselves form a distinctive pattern, or may sequentiallyget larger or smaller in diameter moving towards the center of theadhesive region 50, and that such embodiments are considered within thepurview of the invention.

In some other embodiments, the adhesive 30 may be applied to form apattern within the adhesive region 50. In FIG. 24, an adhesive 30 isapplied in a manner so as to form centrally located circular regions 52that are free or substantially free of adhesive. Although only sevencircular regions 52 are illustrated in FIG. 24, it is to be understoodthat fewer or more circular regions 52 may be present. It is to beunderstood that the regions do not have to be circular in nature andthat adhesive free regions in the adhesive region 50 may have any shape.In another exemplary embodiment, the adhesive 30 may be applied to forma grid-like pattern, such as is depicted in FIG. 25. More specifically,strips of adhesive 54 are positioned within the adhesive region 50 suchthat the strips 54 are substantially parallel to each other withnon-adhesive regions interspacing the adhesive strips 54. It is to beappreciated that strips of adhesive crossing strips 54 in asubstantially perpendicular orientation to form a “grid” (notillustrated) is considered to be within the scope of the invention.

It is to be understood that the patterns of adhesive within the adhesiveregions 50 depicted in FIGS. 21-25 are merely exemplary in nature andthat other adhesive and/or non-adhesive patterns within the adhesiveregion 50 are considered to be within the scope of the invention. It isalso to be appreciated that the adhesive may be distributed uniformly ornon-uniformly within the adhesive region(s) in any pattern within theadhesive region 50.

The adhesive 30 is also applied to the film layer 20 such that thebonded regions 50, together with the unbonded regions 60, create avisible pattern on the surface of the laminate 10. FIG. 3 illustrates anexemplary embodiment where the bonded regions 50 and unbonded regions 60form a visible hexagonal pattern on the exterior surface of the firsttextile 40 of the laminate 10 (shown in FIG. 2). The adhesive 30 may bebreathable or non-breathable and can be applied to the film layer 20 byany conventional manner, such as, but not limited to, gravure printing,screen printing, and transfer printing.

It is to be appreciated that the pattern formed by the bonded andunbonded regions 50, 60, respectively can have any geometric (e.g.,square, circular, rectagonal, octagonal, etc.) or abstract shape, and isgenerally repeated two or more times. In addition, the unbonded regions60 are free or substantially free of adhesive. Further, these unbondedregions 60 may form a continuous path within the laminate 10 that isfree or substantially free of adhesive. In at least the example depictedin FIG. 3, the bonded regions 50 are separated by the unbonded regionsby a distance represented by double sided arrow 80. This unbondeddistance may be greater than about 2 mm, and in exemplary embodiments,may range from about 2 mm to about 20 cm, from about 2 mm to about 10cm, from about 2 mm to 20 mm, or from about 2 mm to about 10 mm. Also,the bonded regions may have a width of at least 2 mm, 3 mm, 4 mm, 5 mm,7 mm, or 10 mm or more. In exemplary embodiments, the width of thebonded region is from about 5 mm to about 10 cm or from about 5 mm toabout 50 mm.

It is to be appreciated that the bonded and unbonded regions 50, 60,respectively can vary in size depending on the desired physicalappearance and attributes. In one or more exemplary embodiment, thewidth of the bonded region is greater than the distance betweenconsecutive bonded regions (e.g., unbonded regions), the “width” beinggenerally defined herein as the greatest distance from one side of theregion to the other.

Additionally, the percent area coverage of the bonded regions in thelaminate may represent greater than or equal to at least 30%, at least40%, or at least 50% of the laminate area, and in some embodiments,greater than or equal to about 60% or 70% or greater. As used herein,the term “percent area coverage of the bonded regions” is defined as thetotal two-dimensional area of adhesive regions within the laminate(although it is not required, the adhesive regions generally form thebonded regions) divided by the total area of the laminate, multiplied by100%. In any event, the amount of adhesive present in the bonded regions50 is greater than the amount of adhesive present in the unbondedregions 60. In exemplary embodiments, the amount of adhesive (e.g., massor volume of adhesive) present in the bonded regions 50 is at least 10%greater, 20% greater, or even 30% greater (or more) than the amount ofadhesive present in the unbonded regions 60. Also, the distance betweenadjacent adhesive dots within the bonded regions 50 may be less than adistance between consecutive bonded regions 50. As used herein, the term“consecutive bonded regions” or “consecutive regions” is meant todescribe adjacent regions. The adhesive may optionally be a fireresistant adhesive or contain a fire resistant or retardant material toprovide fire retardancy to the laminate. Non-limiting examples of fireresistant or retardant materials include, for example, aramids,polybenzimidazole (PBI), poly p-phenylene-2, 6-bezobisoxazole (PBO),modacrylic blends, polyamines, flame resistant rayon, polyamines,carbon, polyacrylonitrile (PAN), and blends and combinations thereof.

The film layer 20 may be a fluoropolymer membrane such as expandedpolytetrafluoroethylene (ePTFE), expanded modifiedpolytetrafluoroethylene, polytetrafluoroethylene (PTFE), ePTFE or PTFEfilms coated with protective coatings such as polyurethanes; polylolefinfilms, polyurethane films; silicone and silicon-containing films; aswell as other fluoropolymer-containing films such as skived PTFE andfluorinated ethylene propylene (FEP); and composites havingpolytetrafluoroethylene membranes. Patents have been filed on expandableblends of PTFE, expandable modified PTFE, and expanded copolymers ofPTFE, such as U.S. Pat. No. 5,708,044 to Branca; U.S. Pat. No. 6,541,589to Baillie; U.S. Pat. No. 7,531,611 to Sabol et al.; U.S. patentapplication Ser. No. 11/906,877 to Ford; and U.S. patent applicationSer. No. 12/410,050 to Xu et al. In at least one exemplary embodiment,the film layer 20 is ePTFE at least partially coated with polyurethane.Alternate protective coatings could be used such as, but not limited to,those described in U.S. Pat. No. 6,395,383 to Maples and U.S. Pat. Nos.5,286,279; 5,342,434; and 5,539,072 to Wu.

The first textile 40 can be any woven, nonwoven, felt, or knit and maybe formed of natural and/or synthetic fiber materials. The first textile40 may be inelastic or elastic or may otherwise be manipulated to changedimensions (e.g., shrink or elongate). As used herein, the term“elastic” is meant to denote a material that can be tensioned and thenreturns to its approximate original dimensions upon release of thetension. It should be understood that elastic properties can be impartedby the textile(s), film layer(s), adhesive(s), or combinations thereof.Non-limiting examples of suitable textiles for use as the first textile40 include nylon, polyester, polypropylene, cotton, wool, silk, aramid,polyethylene, rayon, acrylic, olefin, spandex, and the like.Additionally, the first textile 40 may be a fire resistant or fireretardant textile. The first textile 40 may also contain UV protectivematerials and/or may otherwise be coated or treated to provide desiredcharacteristics.

In at least one embodiment of the invention, a second textile 90 isbonded to the film layer 20 on the side opposing the first textile 40 toform a three-layer laminate 100. The second textile 90 may be any of thetextiles described above with reference to the first textile 40 and maybe the same as or different from the first textile 40. The secondtextile 90 is bonded to the film layer 20 by adhesive 110, which can beapplied in a continuous (i.e., a coherent layer of adhesive within anadhesive region) or discontinuous (i.e., individual, discrete portionsof adhesive within an adhesive region) manner. If applied in acontinuous manner, the adhesive must be breathable in order to maintainthe breathability of the laminate 100. The adhesive need not bebreathable if applied in a suitable discontinuous manner that affordssufficient breathability through the regions without adhesive material.FIG. 4 depicts adhesive 110 as a series of discontinuous dots, althoughthe adhesive may be applied in a discontinuous manner, such as, forexample, as is shown in FIG. 5. The discontinuous application ofadhesive 110 as shown in FIG. 5 results in the formation of bondedregions 120 and unbonded regions 130 on the bottom side of the laminate140. As a result, laminate 140 contains a distinctive pattern on boththe top surface and bottom surface. Although not wishing to be bound bytheory, it is believed that the inclusion of bonded and unbonded regionson both the top and bottom surfaces of the laminate result in a furtherreduction in stiffness, a further reduction in noise, and increasedbreathability. As with adhesive 30, adhesive 110 can be applied to thefilm layer 20 by any known conventional application method. Although notdepicted in FIG. 4 or 5, the bonded regions 50 may contain a continuousadhesive pattern instead of a discontinuous adhesive pattern as shown.

In one or more exemplary embodiment, the film layer 20 and/or the firsttextile 40 is elastic or can otherwise be manipulated to changedimensions (e.g., shrink or elongate). In the instance where the firsttextile 40 is elastic, raised, visible portions of the laminatecorresponding to the unbonded regions 60 are visible as depicted in FIG.6. The raised, visible pattern outlines the geometric or abstract shapeformed by adhesive 30. In addition, the bonded regions 50 exhibit alocalized curling phenomenon 150. It was unexpectedly discovered thatthe unbonded regions 60 not only relieve the residual stresses in thelaminate, they also allow for the introduction of stress (e.g., curl) inthe bonded regions 50 without causing excessive curl in the overalllaminate 160. The localized, aggressive curl 150 in the bonded regions50, separated by flexible unbonded regions 60, increases thethree-dimensional aspect of the laminate 160 and introduces increasedperformance and/or characteristics, such as, but not limited toincreased insulative properties, stretch, spectral properties, andaesthetic characteristics.

The thermal resistance per unit mass of the laminates (e.g. insulativeproperty) of the invention may be greater than or equal to 0.05(m²K/W)/(kg/m²). In at least one exemplary embodiment, the thermalresistance per unit mass of the laminates is from 0.05 (m²K/W)/(kg/m²)to about 0.4 (m²K/W)/(kg/m²). The radius of curvature in the bondedregions 50 may be less than about 50 mm, less than about 20 mm, lessthan about 10 mm, or less than about 6 mm. In addition, the radius ofcurvature may be greater than about 1 mm, greater than about 2 mm,greater than about 3 mm or even greater. In exemplary embodiments, theradius of curvature ranges from about 2 mm to about 50 mm, from about 3mm to about 20 mm, or from about 4 mm to about 10 mm. Also, the laminatemay have a thickness to weight per unit area greater than about 0.005mm/(g/m²), greater than about 0.010 mm/(g/m²), or greater.

Turning now to FIG. 7, the three-dimensional laminate 160 according toat least one exemplary embodiment can best be seen. To form the laminate160, the first textile 40 is stretched a predetermined distance andadhesive 30 is applied to the film layer 20 in an unstretched, relaxedstate. It is to be understood that although the first textile 40 (andfilm layer 20 discussed below) is discussed herein as being stretched inone direction, bi-axially stretching the textile (and film) isconsidered to be within the scope of the invention. As discussed indetail above, adhesive 30 is applied in a discontinuous manner toprovide bonded regions 50 and unbonded regions 60. While the firsttextile 40 is tensioned in a stretched position, the film layer 20containing adhesive 30 is positioned on the first textile 40 to bond thefilm layer 20 to the first textile 40. Upon the release of tension, thefirst textile 40 returns to approximately its original, unstretchedposition. In exemplary embodiments, adhesive 30 is cured prior to therelease of tension.

As the first textile 40 relaxes (“unstretches”), the bonded regions 50curl and the unbonded regions 60 rise. The laminate 160 buckles (e.g.,bunches) in the unbonded regions 60 due, at least in part, to theabsence or substantial absence of adhesive in the unbonded regions 60compared to the bonded regions 50. The terms “buckle” and “bunch” may beused interchangeably herein and are meant to denote the bending of thefilm layer or textile layer upon itself to form the raised portions 65.The difference in the presence of adhesive in the bonded regions 50 andthe unbonded regions 60 permits the laminate to rise (relax) in theunbonded regions 60 and curl in the bonded regions 50. The concavesurface of the bonded regions 50 is positioned toward the textile sideof the laminate. Further, the buckling of the unbonded regions 60 formsan air gap 75 located between the first textile 40 and the film layer 20where the first textile 40 is unbonded to the film layer 20. Thelaminate 160 (and laminate 170 described below) is capable ofpreferentially bending in the unbonded regions 60, which are free orsubstantially free of adhesive. This preferential bending is due, atleast in part, to the fact that the laminate has a lower bending modulusin the unbonded regions 60 compared to the bending modulus in the bondedregions 50. In at least one exemplary embodiment, the bending modulus inthe unbonded regions is at least 20% less, at least 30% less, at least40% less, or at least 50% less (or even less) than the bending modulusof the bonded regions.

A second textile 90 may be bonded to the film layer 20 by adhesive 110as shown in FIG. 8. In this embodiment, the second textile 90 is affixedto the film layer 20 while the first textile 40 is in the stretchedposition described above. As a result, the second textile 90 ispositioned in a substantially planar orientation to the film layer 20.In other words, the second textile 90 substantially follows the path ofthe film layer 20 and buckles with the film layer 20 in the unbondedregions 60 and curls with the first textile 40 in the bonded regions 50when the first textile 40 is released from tension. It is to be notedthat the addition of the second textile 90 does not prohibit thebuckling of the film layer 20 in the unbonded regions 60 or the curlingof the laminate in the bonded regions 50 to form the three dimensionalstructure of the laminate. Although not depicted in FIG. 8, the adhesive110 may be applied in a discontinuous manner to provide bonded andunbonded areas on both the top and bottom surface of laminate 170. Inaddition, the first textile 40 in the raised portions 65 may be at leastpartially coated with an abrasion resistant coating, such as a polymercoating, (not illustrated) to protect the first textile 40 (e.g., outersurface) from wear, such as, for example, when the laminate is used toconstruct a garment.

In an alternate embodiment depicted in FIG. 9, the second textile 90 isbonded to laminate 160 after the first textile 40 is released fromtension and laminate 160 has curled in the bonded regions 50. Adhesive110 may be applied in a discontinuous manner substantially across thelength of the second textile 90 as shown. Alternatively, adhesive 110may be applied in a continuous manner across the second textile 90 or indiscrete portions (either continuously or discontinuously) on only theportion of the laminate 180 where the second textile 90 is in contactwith the film layer 20. As can be seen in FIG. 9, the second textilelayer 90 is substantially flat relative to the film layer 20 and firsttextile 30. By affixing the second textile 90 to the film layer 20 inthis manner, air pockets 190 are formed in the areas defined between thesecond textile 90 and the film layer 20. These air pockets 190 provideadditional insulation value to the laminate 180.

In a further embodiment, the film layer 20 may be either elastic orshrinkable. Looking at FIG. 10, the film layer 20 is bonded to the firsttextile 40 with a discontinuous adhesive 30 that forms a patternedsurface on the laminate 200. In an embodiment where the film layer 20 iselastic, the raised portions 65 in the unbonded regions 60 and curlingin the bonded regions 50 are achieved by applying a first textile 40having thereon adhesive 30 to a tensioned film layer 20. When thetension is released, the laminate curls in the bonded regions 50 towardthe film layer 20. Here, the concave surface of the bonded regions 50 ispositioned towards the film layer side of the laminate. As discussedabove, the difference in the presence of adhesive in the bonded regions50 and the unbonded regions 60 allows the laminate to rise (relax) inthe unbonded regions 60 and curl in the bonded regions 50. Additionally,an air gap 75 is formed between the second textile 40 and the film layer20 in the raised regions 65. In addition, the curled areas correspondingto the bonded regions 50 may be at least partially coated with anabrasion resistant coating, such as a polymer coating, (not illustrated)to protect the first textile 40 (e.g., outer surface) from wear, suchas, for example, when the laminate is used to construct a garment.

Alternatively, where the film layer 20 is shrinkable, the raisedportions 65 in the unbonded regions 60 and the curling in the bondedregions 50 are achieved by shrinking the film layer 20, such as byapplying heat to the film layer 20. As the film layer 20 shrinks, thelaminate 200 curls in the bonded regions 50 toward the film layer 20.The laminate 200 relaxes (rises) in the unbonded regions 60 to relievethe stress caused from shrinking the film layer 20. It is to beunderstood that both a stretchable (i.e., elastic) and shrinkable filmlayer 20 result in the two-layer laminate 200 depicted in FIG. 10. Inembodiments where the film layer 20 is shrinkable or stretchable, thefirst and second textiles 40, 90 are not particularly limited, and mayboth be inelastic.

Alternatively, where the first textile 40 is shrinkable, the raisedportions 65 in the unbonded regions 60 and the curling in the bondedregions 50 are achieved by shrinking the first textile layer 40, such asby applying heat to the first textile layer 40. As the textile layer 40shrinks, the laminate curls in the bonded regions 50 toward the textilelayer 40. The laminate relaxes (rises) in the unbonded regions 60 torelieve the stress caused from shrinking the textile layer 40. Inembodiments where the textile layer 40 is shrinkable or stretchable, thefilm layer 20 and second textile 90 are not particularly limited, andone or both may be inelastic.

A second textile 90 may be affixed to the film layer 20, such as isdepicted in FIG. 11. It is to be appreciated that adhesive 110 may beapplied in a discontinuous manner as shown, or it may be applied indiscrete portions (either continuously or discontinuously) on only theportion of the laminate 210 where the second textile 90 is in contactwith the film layer 20. In the embodiment depicted in FIG. 11, theaddition of the second textile 90 forms air pockets 190 in the areasdefined between the film layer 20 and the second textile 90.

It is to be appreciated that the above-described embodiments arenon-limiting as the three-dimensional nature of the laminate may beachieved by providing at least one layer that is deformable in somemanner, such as, for example, by being elastic, by being shrinkable, bybeing expandable, or any combination thereof. The deformation of one ofthe layers creates stress within the laminate that causes curling of thelaminate within the bonded regions. In turn, the unbonded regions allowthe laminate to buckle, which relieves the stress caused by the curlingof the laminate. The laminates described herein are considerably quieterin use compared to conventional laminates at least partially due to thepreferential bending of the laminate within the unbonded regions.

The laminates described herein may be used in a variety of applications,such as, for example, in garments, as insulation, as spacer material, indiffuse reflective surfaces, or anywhere else that a highly texturizedlaminate may be used. The advantages of the invention as describedherein are numerous, ranging from reduced stiffness and noise toimproved insulation and aesthetic differentiation and improved orenhanced spectral reflection. Spectral reflection is improved orenhanced, at least in part, by the topography (e.g., raised portions) ofthe inventive articles.

Laminates having a reduction in noise may be used in applications wherenoise control is crucial, such as hunting, law enforcement or military,as well applications where noise control is merely desirable, such asconsumer outdoor garments (e.g., jackets, pants, etc.). Embodimentswhich utilize laminate curling include light-weight insulative garmentsfor consumers, fire-fighters, and the like, or reduced contact areablankets and sheets for medical applications.

Testing Methods

It should be understood that although certain methods and equipment aredescribed below, any method or equipment determined suitable by one ofordinary skill in the art may be utilized.

Suter Test for Liquid-proof Fabrics

The Suter Test Method was used to determine if a sample wasliquid-proof. This procedure is based generally on the description inASTM D 751-00, Standard Test Methods for Coated Fabrics (HydrostaticResistance Procedure B2). This procedure provides a low pressurechallenge to the sample being tested by forcing water against one sideof the test sample and observing the other side for indication thatwater has penetrated through the sample.

The test sample was clamped and sealed between rubber gaskets in afixture that held the sample so that water could be applied to aspecific area. The circular area to which water was applied was 4.25inches in diameter. The water was applied at a pressure of 1 psig (0.07bar) to one side of the sample. In testing laminates with one textilelayer the pressurized water was incident upon the film side.

The unpressurized side of the sample was observed visually for any signof water appearing for 3 minutes. If no water was observed the samplewas deemed to have passed the test and was considered liquid-proof. Thereported values were the average of three measurements.

Water Vapor Transmission Rate (WVTR) Test

Water Vapor Transmission Rate (WVTR), i.e. water-vapor-permeability, ismeasured by placing approximately 70 ml of a solution consisting of 35parts by weight of potassium acetate and 15 parts by weight of distilledwater into a 133 ml polypropylene cup having an inside diameter of 6.5cm at its mouth. An ePTFE membrane having a minimum WVTR ofapproximately 85,000 g/m²/day (as tested by the method described in U.S.Pat. No. 4,862,730 to Crosby) was heat sealed to the lip of the cup tocreate a taut, leak-proof, microporous barrier containing the solution.

A similar ePTFE membrane was mounted to the surface of a water bath. Thewater bath assembly was controlled at 23° C.±0.2° C., utilizing atemperature controlled room and a water circulating bath. The sample tobe tested was allowed to condition at a temperature of 23° C. and arelative humidity of about 50% prior to performing the test procedure.Three samples were placed so that each sample to be tested was incontact with the expanded PTFE membrane mounted over the surface of thewater bath and was allowed to equilibrate for at least 15 minutes priorto the introduction of the cup assembly.

The cup assembly was weighed to the nearest 0.001 g and was invertedonto the center of the text sample. Water transport was provided by thedriving force between the water in the water bath and the saturated saltsolution providing water flux by diffusion in that direction. The samplewas tested for 20 minutes and the cup assembly was then removed andweighed again to within 0.001 g.

The WVTR of the sample was calculated from the weight gain of the cupassembly and was expressed in grams of water per square meter of samplesurface area per 24 hours. The reported values were the average of threemeasurements.

Thermal Conductivity Measurement

Thermal conductivity of samples of the present invention was measuredusing a custom-made heat flow meter thermal, conductivity tester atatmospheric conditions (about 298 K and 101.3 kPa). The tester consistedof a heated aluminum plate with a heat flow sensor (ModelFR-025-TH44033, commercially available from Concept Engineering, OldSaybrook, Conn.) and a temperature sensor (thermistor) imbedded in itssurface, and a second aluminum plate maintained at room temperature,also with a temperature sensor imbedded in its surface.

The temperature of the heated plate was maintained at 309.15 K while thetemperature of the “cold” plate was kept at 298.15 K. The diameter ofthe plates was about 10 cm. The heat flow measurement was normallyobtained within about two to five minutes after the sample was placed inthe tester upon reaching a steady state.

Thermal resistance per unit mass was calculated from the measured heatflow and the sample weight according to the formula R_(m)(1/Q−1/Q(0))/w, where R_(m) is thermal resistance per unit mass in(m²K/W)/(kg/m²), Q is normalized heat flow in W/m²K, Q(0) is normalizedheat flow with no sample in place (Q(0)=100 W/m²K), and w is sampleweight in kg/m². The reported values represent the average of threemeasurements.

Radius of Curvature Measurement

The radius of curvature is defined as the radius of the largest circlethat can touch both the top edges and the bottom center of across-section of a curled region, as shown in FIG. 16. To determinethis, the sample was cut perpendicular to the radius of curvature suchthat the cut bisected several curled sections. The width and the depthof the curled sections were then measured with digital calipers andaverage values were obtained.

The radius of curvature was calculated from the average width and depthmeasurements according to the formula: r=c²/(8*a)+(a/2), where r is theradius of curvature in mm, c is the width of the curled section in mmand a is the depth of the curled section in rm. The reported values werethe average of three measurements.

Bending Modulus Measurement

The bending modulus of a 4.68 mm×4.68 mm sample of laminate of thepresent invention was measured using a Thermomechanical Analyzer (ModelQ400 from TA Instruments, New Castle, Del.) using a 3-point bend method.The test was performed at 23° C. The support span was 2.508 mm. Thedeflection rate was approximately 0.162 mm per minute. The samples wereplaced in the test apparatus with the face fabric facing up.

The modulus of each sample was calculated according to the formulaE_(r)=L³ m/(4 bd³), where E_(f) is the bending modulus in MPa, L is thesupport span in mm, m is the slope of the initial straight-line portionof the load-deflection curve in N/mm, b is the width of the test samplein mm, and d is the thickness of the test sample in mm. Sample thicknesswas measured using a digital micrometer (Model ID-C112EX from MitutoyoCorp, Kawasaki, Japan).

Six samples from each region were tested, three in the machine (warp)direction and three in the transverse (weft) direction. The reportedvalues represent the average of all six measurements.

Maximum Thickness to Weight Per Area Ratio Measurement

The maximum thickness of the samples was measured using a digitalmicrometer (Model XLI 40002, Mahr Federal Inc., Providence, R.I.)between two rigid surfaces with an area of 5 cm². It is to be noted thatany suitable means for measuring the maximum thickness (i.e., the heightof the raised regions) and area can be used. The sample weight wasdetermined by cutting a circular portion of the sample 8.9 cm indiameter and weighing it to the nearest 0.001 g. The thickness to weightratio was calculated according to the equation D=T/(W/A), where D is thethickness to weight ratio in mm/(g/m²), T is sample thickness in mm, Wis sample weight in g, and A is the area in m². The reported valuesrepresent the average of three measurements.

Stretch Force Measurement

The force to stretch of the samples was measured using an Instronuniversal testing machine (Model 5565) with a 1000-lb load cell. A3-inch by 8-inch sample of material was cut with the long dimensionoriented in the direction of maximum stretch, A horizontal bar 5 mm indiameter was attached to the load cell of the Instron and pneumaticclamps were attached to the Instron base. The top edge of the horizontalbar was positioned 3″ above the top of the pneumatic clamp grips. Thesample was folded in half parallel to the 3-inch sides and was placedover the horizontal bar. The ends of the sample were clamped together inthe pneumatic clamp grips such that there was neither tension nor slackin the sample. The sample was stretched at a strain rate of 10inches/minute and the load at 20% strain was recorded in lbf. Thereported values represent the average of three measurements.

It would be apparent to one of skill in the art that the laminate may beseparated into its component parts by any suitable means, which mayinclude, but is not limited to, dissolving the adhesive with anappropriate solvent. The stretch force of the textile may then bedetermined.

Thickness

Thickness was measured by placing the membrane or textile laminatebetween the two plates of a Mitutoyo 543-252BS Snap Gauge. The averageof the three measurements was used.

Matrix Tensile Strength (MTS)

Maximum load was measured using an INSTRON 1122 tensile test machineequipped with flat-faced grips and a 0.445 kN load cell. The gaugelength was 5.08 cm and the cross-head speed was 50.8 cm/min. The sampledimensions were 2.54 cm by 15.24 cm. To ensure comparable results, thelaboratory temperature was maintained between 68° F. and 72° F. toensure comparable results. Data was discarded if the sample broke at thegrip interface.

For longitudinal MTS calculations, the larger dimension of the samplewas oriented in the machine, or “down web,” direction. For thetransverse MTS calculations, the larger dimension of the sample wasoriented perpendicular to the machine direction, also known as the“cross web” direction. Each sample was weighed using a Mettler ToledoScale Model AG204. The thickness of the samples was then measured usinga Kafer FZ1000/30 snap gauge. The samples were then tested individuallyon the tensile tester. Three different sections of each sample weremeasured. The average of the three maximum load (i.e., the peak force)measurements was used.

The longitudinal and transverse MTS were calculated using the followingequation:

MTS=(maximum load/cross-section area)*(bulk density of PTFE)/density ofthe porous membrane),

wherein the bulk density of PTFE is taken to be 2.2 g/cc.

The average of three cross-web measurements was recorded as thelongitudinal and transverse MTS.

Density

To calculate density, measurements from the Matrix Tensile Testing wereused. As mentioned above, the sample dimensions were 2.54 cm by 15.24cm. Each sample was weighed using a Mettler Toledo Scale Model AG204 andthen the thickness of the samples was taken using a Kafer FZ1000/30 snapgauge. Using this data, a density of the sample can be calculated withthe following formula:

$\rho = \frac{m}{w*l*t}$

where: ρ=density (g/cc)

-   -   m=mass (g)    -   w=width (1.5 cm)    -   l=length (16.5 cm)    -   t=thickness (cm)

The reported results are the average of 6 calculations.

Bubble Point Pressure

A bubble point test was run according to the general teaching of ASTMF31 6-03. The bubble point is considered the lowest pressure at which acontinuous stream of bubbles were observed rising from the sample. Anopaque or white membrane sample was wet with a wetting liquid such asisopropyl alcohol (IPA) until the sample became transparent ortranslucent. The membrane sample was placed into a filter holder tosecure the sample, and an additional amount of IPA was added to theholder. A first side of the sample was subjected to increasing gaspressure while the second side of the sample was visually monitored withthe unaided eye as the gas pressure was increased. As the gas pressureof the fixture approaches the bubble point pressure, small gas bubblesare observed forming on the top face of the sample. As the pressure isfurther increased, the gas bubbles begin to stream up from the topsurface of the ePTFE membrane, and the pressure at that point isrecorded as the Bubble Point Pressure. The reported results are theaverage 3 measurements.

Having generally described this invention, a further understanding canbe obtained by reference to certain specific examples illustrated belowwhich are provided for purposes of illustration only and are notintended to be all inclusive or limiting unless otherwise specified.

EXAMPLES Example 1

A length of 129 g/m² nylon/Roica® stretch woven material (Style GNS3from Formosa Taffeta Co., Touliu, Taiwan) and a length ofpolyurethane-coated ePTFE were obtained. The ePTFE had the followingproperties: thickness=0.043 mm, density=0.41 g/cc, matrix tensilestrength in the length direction=31×10⁶ MPa, matrix tensile strength inthe width direction=93×10⁶ MPa, Bubble Point=1.5×10⁵ MPa. Polyurethane(PU) was applied by coating the ePTFE membrane and allowing it to atleast partially penetrate the pores of the membrane, then cured.

A release paper 215 was laser cut using the honeycomb (hexagonal)pattern shown in FIG. 12. The hexagonal voids 220 were cut 10 mm wideand were separated by 4 mm wide strips of release paper 230. The releasepaper was positioned onto the ePTFE side of the coated membrane and therelease paper plus membrane were fed into the gravure printer. Althoughnot utilized in this example, in an alternative embodiment shown in FIG.17, a gravure roll 315 having thereon the applied adhesive pattern(shown generally as reference numeral 317 in FIG. 18) may transfer theadhesive to the functional film layer (e.g., coated membrane), thuseliminating the need for release paper 215. A portion 325 of the gravureroll 325 is depicted in FIG. 18 and contains both the adhesive pattern317 and non-adhesive areas 327.

Turning now to FIG. 13, a portion of the processing line for forming atwo-layer laminate can be seen. Another polyurethane 240 was obtainedand loaded in the printer in order to apply heated adhesive dots to theePTFE side of the membrane via roll 250. 500 micron diameter dots wereapplied at a percent area coverage of 39% to the unmasked area of theePTFE membrane 260. As used herein, the term “percent area coverage” ofadhesive is meant to denote the total two-dimensional area of adhesivein a given region divided by the area of that region, multiplied by100%. The stretch woven material was tensioned, the release paper 215(mask) was removed, and the stretch woven textile 270 was placed ontothe adhesive side of the membrane 260. While retaining the tension onthe textile 270, the resulting laminate 280 was spooled onto a roll (notshown) and allowed to moisture cure, which required approximately 2days.

Following moisture curing, the laminate was unspooled and allowed torelax, thereby returning to the initial, untensioned state of thetextile. The hexagonal pattern was visible by the naked eye. The sampleexhibited localized curling in the areas corresponding to the hexagonalvoids in the release paper. The concave surface of these areas wastowards the textile side of the laminate.

The width of the curled sections was 7.3 mm, the depth was 0.9 mm, andthe radius of curvature was 7.8 mm. The resulting laminate weighed 173g/m². The water vapor transmission rate of the sample was 10,048 g/m²/24h. The sample was liquid-proof and breathable. The thermal resistanceper unit mass of the laminate was 0.090 (m²K/W)/(kg/m²). The thicknessto weight per area ratio of the sample was 0.0051 mm/(g/m²).

Example 2

Another laminate was created as described generally in Example 1 withthe following exceptions. The textile was a 93.2 g/m² nylon woven (Style131913 from Milliken, Spartanburg, S.C.), the hexagonal voids in therelease paper were 30 mm wide and were separated by strips of releasepaper 6 mm wide, the textile was not pre-stretched, additional adhesivedots were also applied to the coated side of the ePTFE, and a thirdlayer of textile, a 37.3 g/m² polyester knit (Style A1012 from GlenRaven, Glen Raven, N.C.) was added to the adhesive on the side opposingthe nylon woven textile.

The resulting laminate weighed 180 g/m². The water vapor transmissionrate of the sample was 7,069 g/m²/24 h. The sample was liquid-proof andbreathable. The thermal resistance per unit mass of the laminate was0.024 (m²K/W)/(kg/m²). The thickness to weight per area ratio of thesample was 0.0021 mm/(g/m²). The bending modulus in the bonded regionswas 11.3 MPa. The bending modulus in the unbonded regions was 2.40 MPa.

Example 3

A length of 49.0 g/m² nylon woven material (Style 131907 from Milliken,Spartanburg, S.C.) and a length of ePTFE membrane were obtained. TheePTFE had the following properties: thickness=0.126 mm, density=0.402g/cc, matrix tensile strength in the length direction=28.5×10⁶ Pa,matrix tensile strength in the width direction=144.3×10⁶ Pa, BubblePoint=9.55×10⁴ Pa. The ePTFE membrane was laminated to a 25.4 micronthick, monolithic, thermoplastic polyurethane film (part number PT1710Sfrom Deerfield Urethane, South Deerfield, Ma) using a continuous layerof breathable polyurethane adhesive applied at a coverage rate of 12 to15 g/m². The breathable polyurethane adhesive was a moisture-curedpolyether polyurethane adhesive, as described in U.S. Pat. No. 4,532,316to Robert Henn.

A patterned rubber roll consisting of raised hexagonal areas 290 10 mmwide separated by channels 300 4 mm wide and 2 mm deep was used to pressthe textile into a gravure roll. A portion of such a patterned rubberroll 310 is depicted in FIG. 14. A polyurethane adhesive 240 wasobtained and loaded in the printer in order to apply heated adhesivedots to the textile 320 via roll 250, as shown in FIG. 15. 335 microndiameter dots were applied to the textile 320 at a percent area coverageof 53% primarily in the areas backed by the raised portions of thepatterned rubber roll 310. An ePTFE/PU film 330 was tensioned and the PUside of the film was placed onto the adhesive side of the coatedtextile. While retaining the tension on the ePTFE/PU film 330, theresulting laminate 340 was spooled onto a roll (not illustrated) andallowed to moisture cure, which required approximately 2 days.

Following moisture curing, the laminate was unspooled and allowed torelax, thereby returning to the initial, untensioned state of the film.The hexagonal pattern was visible by the naked eye. The sample exhibitedlocalized curling in the areas corresponding to the raised hexagonalareas of the patterned rubber roll. The concave surface of these areaswas towards the film side of the laminate.

The width of the curled sections was 6.7 mm, the depth was 2.3 mm andthe radius of curvature was 3.6 mm. The resulting laminate weighed 202g/m². The water vapor transmission rate of the sample was 4,243 g/m²/24h. The sample was liquid-proof and breathable. The thermal resistanceper unit mass of the laminate was 0.204 (m²K/W)/(kg/m²). The thicknessto weight per area ratio of the sample was 0.010 mm/(g/m²).

Example 4

A length of 137.7 g/m̂2 nylon/elastane stretch woven material (StyleQ4410 from Chia Her Industrial Co., Taipei, Taiwan) and a length ofpolyurethane-coated ePTFE were obtained. The ePTFE had the followingproperties: thickness=0.043 mm, density=0.41 g/cc, matrix tensilestrength in the length direction=31×10⁶ MPa, matrix tensile strength inthe width direction=93×10⁶ MPa, Bubble Point=1.5×10⁵ MPa. Polyurethane(PU) was applied by coating the ePTFE membrane and allowing it to atleast partially penetrate the pores of the membrane, then cured.

A release paper 215 was laser cut using the honeycomb (hexagonal)pattern shown in FIG. 12. The hexagonal voids 220 were cut 10 mm wideand were separated by 4 mm wide strips of release paper 230. The releasepaper was positioned onto the ePTFE side of the coated membrane and therelease paper plus membrane were fed into the gravure printer. In analternative embodiment shown in FIG. 17, a gravure roll 315 havingthereon the applied adhesive pattern (shown generally as 317 in FIG. 18)may transfer the adhesive to the functional film layer (e.g., coatedmembrane), thus eliminating the need for release paper 215. A portion ofthe gravure roll 325 is depicted in FIG. 18 and contains both theadhesive pattern 317 and non-adhesive areas 327.

Turning now to FIG. 13, a portion of the processing line for forming atwo-layer laminate can be seen. Another polyurethane 240 was obtainedand loaded in the printer in order to apply heated adhesive dots to theePTFE side of the membrane via roll 250, 305 micron wide square adhesivedots were applied at a percent area coverage of 83% to the unmasked areaof the ePTFE membrane 260. As used herein, the term “percent areacoverage” of adhesive is meant to denote the total two-dimensional areaof adhesive in a given region divided by the area of that region,multiplied by 100%. The stretch woven material was tensioned, therelease paper 215 (mask) was removed, and the stretch woven textile 270was placed onto the adhesive side of the membrane 260. While retainingthe tension on the textile 270, the resulting laminate 280 was spooledonto a roll (not shown) and allowed to moisture cure, which requiredapproximately 2 days.

Following moisture curing, the laminate was unspooled and allowed torelax, thereby returning to the initial, untensioned state of thetextile. The hexagonal pattern was visible by the naked eye. The sampleexhibited localized curling in the areas corresponding to the hexagonalvoids in the release paper. The concave surface of these areas wastowards the textile side of the laminate.

The width of the curled sections was 6.37 mm, the depth was 2.54 mm, andthe radius of curvature was 3.27 mm. The resulting laminate weighed194.5 g/m². The water vapor transmission rate of the sample was 4470g/m²/24 h. The sample was liquid-proof and breathable. The thickness toweight per area ratio of the sample was 0.014 mm/(g/m²). The stretchforce of the sample at 20% strain was 0.23 lbf. The stretch force of theraw stretch woven material at 20% strain was 0.73 lbf.

Comparative Example 1

A comparative prior art stretch material was assembled in the followingmanner and tested as described for coparison purposes. A length of 137.7g/m̂2 nylon/elastane stretch woven material (Style Q4410 from Chia HerIndustrial Co., Taipei, Taiwan) and a length of polyurethane-coatedePTFE were obtained. The ePTFE had the following properties:thickness=0.043 mm, density=0.41 g/cc, matrix tensile strength in thelength direction=31×10⁶ MPa, matrix tensile strength in the widthdirection=93×10⁶

MPa, Bubble Point=1.5×10⁵ MPa. Polyurethane (PU) was applied by coatingthe ePTFE membrane and allowing it to at least partially penetrate thepores of the membrane, then cured.

Turning now to FIG. 13, a portion of the processing line for forming atwo-layer laminate can be seen. Another polyurethane 240 was obtainedand loaded in the printer in order to apply heated adhesive dots to theePTFE side of the membrane via roll 250. 500 micron diameter adhesivedots were applied at a percent area coverage of 40% to the ePTFEmembrane 260. As used herein, the term “percent area coverage” ofadhesive is meant to denote the total two-dimensional area of adhesivein a given region divided by the area of that region, multiplied by100%. The stretch woven material 270 was tensioned and placed onto theadhesive side of the membrane 260. While retaining the tension on thetextile 270, the resulting laminate 280 was spooled onto a roll (notshown) and allowed to moisture cure, which required approximately 2days.

Following moisture curing, the laminate was unspooled and allowed torelax, thereby returning to the initial, untensioned state of thetextile.

The resulting laminate weighed 164, 4 g/m². The water vapor transmissionrate of the sample was 13540 g/m²/24 h. The sample was liquid-proof andbreathable The thickness to weight per area ratio of the sample was0.0035 mm/(g/m²). The stretch force of the sample at 20% strain was 5.25lbf.

Example 5

A length of 49.0 g/m² nylon woven material (Style 131907 from Milliken,Spartanburg, S.C.) and a length of ePTFE membrane were obtained. TheePTFE had the following properties: thickness=0.043 mm, density=0.41g/cc, matrix tensile strength in the length direction=31×10⁶ MPa, matrixtensile strength in the width direction=93×10⁶ MPa, Bubble Point=1.5×10⁵MPa. The ePTFE membrane was laminated to a 25.4 micron thick,monolithic, thermoplastic polyurethane film (part number PT1710S fromDeerfield Urethane, South Deerfield, Ma) using a continuous layer ofbreathable polyurethane adhesive applied at a coverage rate of 12 to 15g/m². The breathable polyurethane adhesive was a moisture-curedpolyether polyurethane adhesive, as described in U.S. Pat. No. 4,532,316to Robert Henn.

A release paper 215 was laser cut using the honeycomb (hexagonal)pattern shown in FIG. 12. The hexagonal voids 220 were cut 10 mm wideand were separated by 4 mm wide strips of release paper 230. The releasepaper was positioned onto the woven material and the release paper pluswoven material were fed into the gravure printer. In an alternativeembodiment shown in FIG. 17, a gravure roll 315 having thereon theapplied adhesive pattern (shown generally as 317 in FIG. 18) maytransfer the adhesive to the woven material thus eliminating the needfor release paper 215. A portion of the gravure roll 325 is depicted inFIG. 18 and contains both the adhesive pattern 317 and non-adhesiveareas 327.

Turning now to FIG. 13, a portion of the processing line for forming atwo-layer laminate can be seen. Another polyurethane 240 was obtainedand loaded in the printer in order to apply heated adhesive dots to thewoven material via roll 250. 305 micron wide square adhesive dots wereapplied at a percent area coverage of 83% to the unmasked area of thewoven material 320. As used herein, the term “percent area coverage” ofadhesive is meant to denote the total two-dimensional area of adhesivein a given region divided by the area of that region, multiplied by100%. The ePTFE/polyurethane film was tensioned, the release paper 215(mask) was removed, and the ePTFE/polyurethane film 330 was placed ontothe adhesive side of the woven material 320. While retaining the tensionon the ePTFE/polyurethane film 330, the resulting laminate 340 wasspooled onto a roll (not shown) and allowed to moisture cure, whichrequired approximately 2 days.

Following moisture curing, the laminate was unspooled and allowed torelax, thereby returning to the initial, untensioned state of the film.The hexagonal pattern was visible by the naked eye. The sample exhibitedlocalized curling in the areas corresponding to the hexagonal voids inthe release paper. The concave surface of these areas was towards thefilm side of the laminate.

The width of the curled sections was 6.07 mm, the depth was 2.88 mm andthe radius of curvature was 3.04 mm. The resulting laminate weighed 247g/m². The water vapor transmission rate of the sample was 3255 g/m²/24h. The sample was liquid-proof and breathable. The thickness to weightper area ratio of the sample was 0.013 mm/(g/m²). The stretch force ofthe sample at 20% strain was 0.77 lbf. The stretch force of the rawePTFE/polyurethane film at 20% strain was 6.63 lbf.

Comparative Example 2

A comparative prior art stretch material was assembled in the followingmanner and tested as described for coparison purposes. A length of 49.0g/m² nylon woven material (Style 131907 from Milliken, Spartanburg,S.C.) and a length of ePTFE membrane were obtained. The ePTFE had thefollowing properties: thickness=0.043 mm, density=0.41 g/cc, matrixtensile strength in the length direction=31×10⁶ MPa, matrix tensilestrength in the width direction=93×10⁶ MPa, Bubble Point=1.5×10⁵

MPa. The ePTFE membrane was laminated to a 25.4 micron thick,monolithic, thermoplastic polyurethane film (part number PT1710S fromDeerfield Urethane, South Deerfield, Ma) using a continuous layer ofbreathable polyurethane adhesive applied at a coverage rate of 12 to 15g/m². The breathable polyurethane adhesive was a moisture-curedpolyether polyurethane adhesive, as described in U.S. Pat. No. 4,532,316to Robert Henn.

Turning now to FIG. 13, a portion of the processing line for forming atwo-layer laminate can be seen. Another polyurethane 240 was obtainedand loaded in the printer in order to apply heated adhesive dots to thewoven material via roll 250. 390 micron wide square adhesive dots wereapplied at a percent area coverage of 15.5% to the unmasked area of thewoven material 320. As used herein, the term “percent area coverage” ofadhesive is meant to denote the total two-dimensional area of adhesivein a given region divided by the area of that region, multiplied by100%. The ePTFE/polyurethane film 330 was tensioned and was placed ontothe adhesive side of the woven material 320. While retaining the tensionon the ePTFE/polyurethane film 330, the resulting laminate 340 wasspooled onto a roll (not shown) and allowed to moisture cure, whichrequired approximately 2 days.

Following moisture curing, the laminate was unspooled and allowed torelax, thereby returning to the initial, untensioned state of the film.

The resulting laminate weighed 149.2 g/m². The water vapor transmissionrate of the sample was 6784 g/m²/24 h. The sample was liquid-proof andbreathable. The thickness to weight per area ratio of the sample was0.0036 mm/(g/m²). The stretch force of the sample at 20% strain was 6.39lbf.

Example 6

A length of 79.4 g/m² polyester knit material (Style MT-O50 from TahTong

Textile Co., Taipei, Taiwan) and a length of polyurethane-coated ePTFEwere obtained. The ePTFE had the following properties; thickness=0.043mm, density=0.41 g/cc, matrix tensile strength in the lengthdirection=31×10⁶ MPa, matrix tensile strength in the widthdirection=93×10⁶ MPa, Bubble Point=1.5×10⁵ MPa. Polyurethane (PU) wasapplied by coating the ePTFE membrane and allowing it to at leastpartially penetrate the pores of the membrane, then cured.

A release paper 410 was laser cut using the pattern shown in FIG. 19.The dimension of the voids 420 was 3 mm wide by 27 mm in length and wereseparated by 5 mm wide strips of release paper 410. The release paper410 was positioned onto the ePTFE side of the coated membrane and therelease paper plus membrane were fed into the gravure printer.

Referring generally to FIG. 13, with the exception that the releasepaper 410, with the longer lengths of the voids 420 oriented in themachine direction, was substituted for release paper 215, a portion ofthe processing line for forming a two-layer laminate can be seen.Another polyurethane 240 was obtained and loaded in the printer in orderto apply heated adhesive dots to the ePTFE side of the membrane via roll250. Adhesive was applied to the unmasked area of the ePTFE membrane260. The release paper 410 (mask) was removed, and the knit material 270was placed onto the adhesive side of the membrane 260. While retainingthe tension on the knit 270, the resulting laminate 280 was spooled ontoa roll (not shown) and allowed to moisture cure, which requiredapproximately 2 days.

Following moisture curing, the laminate was unspooled and allowed torelax, thereby returning to the initial, untensioned state of thetextile. This reduction in tension allowed the knit to expand in thecrossweb direction, i.e., the direction perpendicular in the plane ofthe textile to the knit rows of the knitted textile, which resulted inbuckling and folding of the knit in the areas not corresponding to thevoids in the release paper.

The resulting laminate weighed 298 g/m². The thickness to weight perarea ratio of the sample was 0.0077 mm/(g/m²). The water vaportransmission rate of the sample was 6480 g/m²/24 h. The sample wasliquid-proof and breathable.

The invention of this application has been described above bothgenerically and with regard to specific embodiments. The invention isnot otherwise limited, except for the recitation of the claims set forthbelow.

Having thus described the invention, what is claimed is:
 1. A laminatedarticle comprising: a functional film layer; a first textile; and afirst adhesive layer bonding said functional film layer and said firsttextile, said first adhesive layer containing two or more adhesiveregions separated by regions substantially free of adhesive, each saidadhesive region containing a plurality of adhesive dots, wherein adistance between adjacent adhesive dots within said adhesive regions isless than a distance between consecutive adhesive regions, wherein saidadhesive regions have at least one distinctive shape, and wherein saidlaminate has a stretch force at 20% elongation of less than three timesthe stretch force of said first textile.
 2. The laminated article ofclaim 1, wherein said laminate has a stretch force at 20% elongation ofless than two times the stretch force of said first textile.
 3. Thelaminated article of claim 1, wherein said laminate has a stretch forceat 20% elongation of less than the stretch force of said first textile.4. The laminated article of claim 1, wherein said laminate has a stretchforce at 20% elongation of less than 0.5 times the stretch force of saidfirst textile.
 5. The laminated article of claim 1, wherein saidlaminate has a stretch force at 20% elongation of less than 0.33 timesthe stretch force of said first textile.
 6. The laminated article ofclaim 1, wherein said laminate has a stretch force at 20% elongation ofless than 0.16 times the stretch force of said first textile.
 7. Thelaminated article of claim 1, wherein said plurality of adhesive dotsare distributed non-uniformly within said adhesive regions.
 8. Thelaminated article of claim 1, wherein said functional film layer is afluoropolymer.
 9. The laminated article of claim 1, wherein saidfunctional film layer is selected from expanded polytetrafluoroethylene(ePTFE), expanded modified polytetrafluoroethylene,polytetrafluoroethylene (PTFE), ePTFE coated with a protective coating,PTFE coated with a protective coating, polyurethane and combinationsthereof.
 10. The laminated article of claim 1, wherein said functionalfilm layer is waterproof and breathable.
 11. The laminated article ofclaim 1, wherein said plurality of adhesive dots each have substantiallythe same size.
 12. The laminated article of claim 1, wherein saidadhesive dots differ in size within said adhesive regions.
 13. Thelaminated article of claim 1, wherein adhesive dots positioned on anouter portion of said adhesive regions have a diameter that is largerthan adhesive dots positioned on an inner portion of said adhesiveregions.
 14. A laminated article comprising: a functional film layer; afirst textile; and a first adhesive layer bonding said functional filmlayer and said first textile, said first adhesive layer containingadhesive regions and regions substantially free of adhesive, whereinsaid regions substantially free of adhesive are interspaced between saidadhesive regions, wherein said laminate has a stretch force at 20%elongation of less than three times the stretch force of said firsttextile.
 15. The laminated article of claim 14, wherein said laminatehas a stretch force at 20% elongation of less than two times the stretchforce of said first textile.
 16. The laminated article of claim 14,wherein said laminate has a stretch force at 20% elongation of less thanthe stretch force of said first textile.
 17. The laminated article ofclaim 14, wherein said laminate has a stretch force at 20% elongation ofless than 0.5 times the stretch force of said first textile.
 18. Thelaminated article of claim 14, wherein said laminate has a stretch forceat 20% elongation of less than 0.33 times the stretch force of saidfirst textile.
 19. The laminated article of claim 14, wherein saidlaminate has a stretch force at 20% elongation of less than 0.16 timesthe stretch force of said first textile.
 20. The laminated article ofclaim 14, wherein said laminated article preferentially bends in saidregions substantially free of adhesive.
 21. The laminated article ofclaim 14, wherein said regions substantially free of adhesive have awidth greater than about 2 mm.
 22. The laminated article of claim 14,wherein said functional film layer is a fluoropolymer.
 23. The laminatedarticle of claim 14, wherein said functional film layer is selected fromexpanded polytetrafluoroethylene (ePTFE), expanded modifiedpolytetrafluoroethylene, polytetrafluoroethylene (PTFE), ePTFE coatedwith a protective coating, PTFE coated with a protective coating,polyurethane and combinations thereof.
 24. The laminated article ofclaim 14, wherein at least one of said first adhesive regions comprise asubstantially continuous band of adhesive surrounding a plurality ofadhesive dots.
 25. The laminated article of claim 24, wherein saidplurality of adhesive dots have substantially the same size.
 26. Thelaminated article of claim 24, wherein said plurality of adhesive dotsdiffer in size.
 27. The laminated article of claim 14, wherein at leastone of said first adhesive regions comprise strips of adhesivepositioned within the adhesive region such that the strips of adhesiveare substantially parallel to each other with said regions substantiallyfree of adhesive interspacing said strips of adhesive.
 28. The laminatedarticle of claim 14, wherein at least one of said first adhesive regionscomprise centrally located regions that are free or substantially freeof adhesive.
 29. The laminated article of claim 14, wherein saidfunctional film layer is waterproof and breathable.
 30. A laminatedarticle comprising: a functional film layer; a first textile; and afirst adhesive layer bonding said functional film layer and said firsttextile, said first adhesive layer containing first adhesive regions andsecond adhesive regions, wherein said first adhesive regions contain anamount of adhesive that is greater than an amount of adhesive present insaid second adhesive regions, and wherein said laminate has a stretchforce at 20% elongation of less than three times the stretch force ofsaid first textile.
 31. The laminated article of claim 30, wherein saidlaminate has a stretch force at 20% elongation of less than two timesthe stretch force of said first textile.
 32. The laminated article ofclaim 30, wherein said laminate has a stretch force at 20% elongation ofless than the stretch force of said first textile.
 33. The laminatedarticle of claim 30, wherein said laminate has a stretch force at 20%elongation of less than 0.5 times the stretch force of said firsttextile.
 34. The laminated article of claim 30, wherein said laminatehas a stretch force at 20% elongation of less than 0.33 times thestretch force of said first textile.
 35. The laminated article of claim30, wherein said laminate has a stretch force at 20% elongation of lessthan 0.16 times the stretch force of said first textile.
 36. Thelaminated article of claim 30, wherein the distribution of adhesivewithin said first adhesive regions is non-uniform.
 37. The laminatedarticle of claim 30, wherein said functional film layer is afluoropolymer.
 38. The laminated article of claim 30, wherein saidfunctional film layer is selected from expanded polytetrafluoroethylene(ePTFE), expanded modified polytetrafluoroethylene,polytetrafluoroethylene (PTFE), ePTFE coated with a protective coating,PTFE coated with a protective coating, polyurethane and combinationsthereof.
 39. The laminated article of claim 30, wherein said functionalfilm layer is waterproof and breathable.
 40. A laminated articlecomprising: a functional film layer; a first textile bonded to saidfunctional film layer by a first adhesive layer, said first adhesivelayer containing at least one first region having a first percent areacoverage of adhesive and at least one second region having a secondpercent area coverage of adhesive, said first percent area coverage ofadhesive being greater than said second area coverage of adhesive,wherein said first region forms at least one distinctive shape, said atleast one shape being repeated two or more times and wherein saidlaminate has a stretch force at 20% elongation of less than three timesthe stretch force of said first textile.
 41. The laminated article ofclaim 40, wherein said laminate has a stretch force at 20% elongation ofless than two times the stretch force of said first textile.
 42. Thelaminated article of claim 40, wherein said laminate has a stretch forceat 20% elongation of less than the stretch force of said first textile.43. The laminated article of claim 40, wherein said laminate has astretch force at 20% elongation of less than 0.5 times the stretch forceof said first textile.
 44. The laminated article of claim 40, whereinsaid laminate has a stretch force at 20% elongation of less than 0.33times the stretch force of said first textile.
 45. The laminated articleof claim 40, wherein said laminate has a stretch force at 20% elongationof less than 0.16 times the stretch force of said first textile.
 46. Thelaminated article of claim 40, wherein the distribution of adhesivewithin at least one of said first adhesive region and said secondadhesive region is non-uniform.
 47. The laminated article of claim 40,wherein said functional film layer is a fluoropolymer.
 48. The laminatedarticle of claim 40, wherein said functional film layer is selected fromexpanded polytetrafluoroethylene'(ePTFE), expanded modifiedpolytetrafluoroethylene, polytetrafluoroethylene (PTFE), ePTFE coatedwith a protective coating, PTFE coated with a protective coating,polyurethane and combinations thereof.
 49. The laminated article ofclaim 40, wherein said functional film layer is waterproof andbreathable.
 50. A method of forming a laminated article comprising:tensioning a first textile; bonding a functional film layer and saidfirst textile via a first adhesive layer, said first adhesive layercontaining adhesive regions and regions substantially free of adhesive;and allowing said first textile to relax resulting in curling of thelaminated article in the areas corresponding to the adhesive regions,wherein said regions substantially free of adhesive are interspacedbetween said adhesive regions and said adhesive regions have at leastone distinctive shape, wherein said laminated article preferentiallybends in said regions substantially free of adhesive, and wherein saidlaminate has a stretch force at 20% elongation of less than three timesthe stretch force of said first textile.
 51. The method of claim 50,wherein said laminate has a stretch force at 20% elongation of less thantwo times the stretch force of said first textile.
 52. The method ofclaim 50, wherein said laminate has a stretch force at 20% elongation ofless than the stretch force of said first textile.
 53. The method ofclaim 50, wherein said laminate has a stretch force at 20% elongation ofless than 0.5 times the stretch force of said first textile.
 54. Themethod of claim 50, wherein said laminate has a stretch force at 20%elongation of less than 0.33 times the stretch force of said firsttextile.
 55. The method of claim 50, wherein said laminate has a stretchforce at 20% elongation of less than 0.16 times the stretch force ofsaid first textile.
 56. The method of claim 50, wherein the distributionof adhesive within said first adhesive regions is non-uniform.
 57. Themethod of claim 50, wherein said functional film layer is afluoropolymer.
 58. The method of claim 50, wherein a distance betweenconsecutive said adhesive regions is greater than about 2 mm
 59. Themethod of claim 50, wherein said functional film layer is selected fromexpanded polytetrafluoroethylene (ePTFE), expanded modifiedpolytetrafluoroethylene, polytetrafluoroethylene (PTFE), ePTFE coatedwith a protective coating, PTFE coated with a protective coating,polyurethane and combinations thereof.
 60. The method of claim 50,wherein said functional film layer is waterproof and breathable.
 61. Amethod of forming a laminated article comprising: tensioning afunctional film layer; bonding said tensioned functional film layer to afirst textile via a first adhesive layer, said first adhesive layercontaining adhesive regions and regions substantially free of adhesiveto form a laminated article; allowing said laminated article to relaxresulting in curling of the laminated article in the areas correspondingto the adhesive regions, wherein said regions substantially free ofadhesive are interspaced between said adhesive regions and said adhesiveregions have at least one distinctive shape, and wherein said laminatehas a stretch force at 20% elongation of less than three times thestretch force of said first textile.
 62. The method of claim 61, whereinsaid laminate has a stretch force at 20% elongation of less than twotimes the stretch force of said functional film layer.
 63. The method ofclaim 61, wherein said laminate has a stretch force at 20% elongation ofless than the stretch force of said functional film layer.
 64. Themethod of claim 61, wherein said laminate has a stretch force at 20%elongation of less than 0.5 times the stretch force of said functionalfilm layer.
 65. The method of claim 61, wherein said laminate has astretch force at 20% elongation of less than 0.33 times the stretchforce of said functional film layer.
 66. The method of claim 61, whereinsaid laminate has a stretch force at 20% elongation of less than 0.16times the stretch force of said functional film layer.
 67. The method ofclaim 61, wherein a distance between consecutive said adhesive regionsis greater than about 2 mm.
 68. The method of claim 61, wherein thedistribution of adhesive within said first adhesive regions isnon-uniform.
 69. The method of claim 61, wherein said functional filmlayer is a fluoropolymer.
 70. The method of claim 61, wherein saidfunctional film layer is selected from expanded polytetrafluoroethylene(ePTFE), expanded modified polytetrafluoroethylene,polytetrafluoroethylene (PTFE), ePTFE coated with a protective coating,PTFE coated with a protective coating, polyurethane and combinationsthereof.
 71. The method of claim 61, wherein said functional film layeris waterproof and breathable.
 72. The method of claim 61, furthercomprising bonding an elastomeric film layer to said functional filmlayer prior to tensioning said functional film layer.
 73. The method ofclaim 72, wherein said functional film layer is selected from expandedpolytetrafluoroethylene (ePTFE), expanded modifiedpolytetrafluoroethylene, polytetrafluoroethylene (PTFE), ePTFE coatedwith a protective coating, PTFE coated with a protective coating,polyurethane and combinations thereof.
 74. A laminated articlecomprising: a functional film layer; a first textile; and a firstadhesive layer bonding said functional film layer and said firsttextile, said first adhesive layer containing adhesive regions andregions substantially free of adhesive, wherein said regionssubstantially free of adhesive are interspaced between said adhesiveregions, wherein the distribution of adhesive within said adhesiveregions is non-uniform.
 75. The laminated article of claim 74, whereinsaid regions substantially free of adhesive have a width greater thanabout 2 mm.
 76. A method of forming a laminated article comprising:bonding a shrinkable functional film layer to a first textile via afirst adhesive layer to form a laminated article, said first adhesivelayer containing adhesive regions and regions substantially free ofadhesive; shrinking said functional film, resulting in curling of thelaminated article in the areas corresponding to the adhesive regions,wherein said regions substantially free of adhesive are interspacedbetween said adhesive regions and said adhesive regions have at leastone distinctive shape.
 77. The method of claim 76, wherein saidlaminated article curls towards the functional film layer.
 78. Themethod of claim 76, further comprising adhering a second textile to saidshrunk functional film on a side of said shrunk functional film opposingsaid first textile.
 79. A method of forming a laminated articlecomprising: bonding a functional film layer to a shrinkable textile viaa first adhesive layer to form a laminated article, said first adhesivelayer containing adhesive regions and regions substantially free ofadhesive, shrinking said textile, resulting in curling of the laminatedarticle in the areas corresponding to the adhesive regions; and whereinsaid regions substantially free of adhesive are interspaced between saidadhesive regions and said adhesive regions have at least one distinctiveshape.
 80. The method of claim 79, wherein said laminated article curlstowards the shrunk textile.